DE202020005798U1 - Using a water jet to separate the uncured rubber compound from the steel cord - Google Patents

Abstract

Use of a water jet under pressure from 500 to 3000 bar with a flow rate of 15 l/min and higher with a reverse osmosis system or a similar water purification system (9) to separate an unvulcanized rubber compound from steel cord into scrap / rubberized steel cord waste while maintaining the physical- mechanical and physico-chemical properties/values of the original rubber compound, including the impact on the technical rubber product.

Description

The invention relates to the rubber industry, in particular to industrial waste processing and the manufacture of rubber compounds. Most effectively, the proposed use can be applied in industrial enterprises that produce tires and technical rubber products, as well as in local enterprises that carry out economic activities by processing scrap / waste rubberized steel cords.

The problem of recycling scrap / waste rubberized steel cord not vulcanized with rubber compound is the task of using the valuable raw materials from which these products are made as efficiently as possible. The production of secondary raw materials is an important resource-saving direction against the background of the increasing scarcity of natural resources and the annually increasing costs of primary raw materials.

The economic necessity of processing such raw materials lies in the fact that they retain their properties and can be used both as intended and in other industries. The secondary raw materials successfully replace expensive primary raw materials and do not differ in physical-mechanical and physical-chemical values from recognized, usual rubber compounds.

With current technical possibilities, there are various disposal and recycling processes for scrap / waste rubberized steel cord.

The simplest method of disposing of rubberized steel cord scrap/waste is incineration.

This process is dangerous and harmful to the environment. Burning is also frowned upon by the population and is a punishable offence.

In addition, technical thermal utilization of rubberized steel cord as a processing method is known - pyrolysis (e.g. RF Patent for Utility Model No. 46222, IPC B29B 17/00, C10B 53/00, published on June 27, 2005), which consists of the utilized/ processed technical rubber products produces carbon black and a range of liquid and gaseous organic substances that can be used in the chemical and energy industries. Pyrolysis is usually carried out after the products have been destroyed and ground. It should also be noted here that this process is used for vulcanized scrap / waste from technical rubber products.

The main disadvantage of pyrolysis is that using this method does not solve the problem of processing the total amount of waste products, especially rubberized steel cord, since the consumption volume of the pyrolysis products is limited. Disadvantages are also the high energy consumption of the process and the need to heat the processed products at high temperatures, exceeding 1 kWh/kg. If the vulcanized scrap / waste is used / recycled in this way, then it is not possible to return the valuable raw materials - e.g. non-vulcanized rubber compound - to the production cycle.

The technical possibility of converting rubber to an embrittled state by cooling it to the glass transition temperature using cryogenic technology is known. This makes it possible to reduce energy costs for grinding and to separate reinforcing elements from the product before mechanical processing (B. RF Patent for Invention No. 2111859, IPC B29B 17/00, C08J 11/10, published 05/27/1998) . This approach is implemented in the processing of technical rubber products. This process is also used for vulcanized scrap / waste, which in turn means that the most valuable raw material - non-vulcanized rubber compound - cannot be returned to the production cycle.

The reason for this is that raw (unvulcanized) rubber cannot be subjected to a cooling process until it becomes brittle due to its properties.

Technically, the processing of rubberized steel cord scrap/waste by mechanical methods is known, such as crushing (crushing technique), cutting (shredder) and grinding (with rollers) (e.g. RF Patent for Invention No. 2325995, IPC B29B 17/00, published on 12/27/2007). This process is used for vulcanized scrap/waste technical rubber products. As a result, the most valuable raw material - non-vulcanized rubber compound - cannot be returned to the production cycle.

The disadvantage is that the processing of rubberized steel cord scrap/waste and the production of rubber crumbs by mechanical methods is not possible, since the viscosity of raw/unvulcanized rubber does not allow crushing, cutting and grinding of the submitted material.

Thus, the processing of scrap / waste from rubberized steel cord (unvulcanized rubber) and high-quality material separation is a complex technical problem. An ecological and economically satisfactory solution has not yet been found anywhere in the world.

In order to use the rubber compound for the production of rubberized steel cord in the tire industry, for the manufacture (after vulcanization of the rubber compound) of consumer goods or special products for various economic sectors, certain technical quality requirements must be met, including and in particular the limitation of the content of volatile components (metal, dust, moisture, chemical contamination, etc.). To do this, it is necessary to ensure the separation of rubber and metal fragments of the carcass. The viscosity of raw rubber, the lack of a chemical bond with the metal and not losing its original properties in aggressive environments was the basis for a study of this problem. This led to solving the problem of obtaining expensive secondary raw materials.

The essence of this invention is that the non-vulcanized rubber mixture is removed from the steel cord in technical rubber products under a pressurized water jet of 500 to 3000 bar with a flow rate of 15 l/m and more through water prepared by a reverse osmosis system while maintaining physical/mechanical measured values and physical / chemical measurements of the primary vulcanized rubber compound is separated. A similar water purification system or domestic water heating up to 150°C can also be used for this.

The technical result is an increase in profitability with high-quality separation of substances during processing, a reduction in wear and tear of equipment for processing after this use, a reduction in energy consumption and an increase in environmental safety. The application of the invention ensures the reduction of waste and rejects in the production of the tire and rubber industry, the introduction of a recycled product in the tire and rubber industry, as well as the introduction of a new product as a masterbatch for various industries both as consumer goods and specialty products (petroleum -, gas production and processing complex, transportation industry, automotive industry, aerospace industry, etc.).

The invention is illustrated/illustrated by the following drawings.

• 1 eine allgemeine Ansicht von Schrott / Abfall des gummiertem Stahlcords (nicht vulkanisierte Gummimischung).
• 2 die extrahierten Gummifragmente von nicht vulkanisierter Gummimischung.
• 3 die extrahierten Metallverstärkungen (Fäden) des Stahlcords.
• 4 die Aufteilung des eingehenden Materials in Metallverstärkungselemente und Gummifragmente.
• 5 die Gummimischung nach der Verarbeitung.
• 6 eine schematische Darstellung einer Vorrichtung zum Trennen einer nicht vulkanisierten Gummimischung von Stahlcord bei Schrott / Abfall. Dabei ist

  1

  Arbeitskammer,

  2

  automatische Tore zum Beladen von Rohstoffen und Entladen von verarbeiteten Produkten,

  5

  Reinigungssystem,

  6

  Arbeitstisch,

  8

  fließendes Wasser eines Wasserversorgungssystems mit einer Wasserumkehrosmoseanlage,

  11

  Fernbedienung für das Reinigungssystem,

  12

  Wassertank.

• 7 eine schematische Darstellung einer Vorrichtung zum Trennen einer nicht vulkanisierten Gummimischung von Stahlcord im Schrott / Abfall. Dabei ist

  1

  Arbeitskammer,

  4

  Hochdruckgerät,

  7

  Wasserumlaufsystem,

  8

  fließendes Wasser eines Wasserversorgungssystems,

  11

  Fernbedienung für das Reinigungssystem,

  12

  Wassertank.

• 8 eine schematische Darstellung einer Vorrichtung zum Trennen einer nicht vulkanisierten Gummimischung von Stahlcord bei Schrott / Abfall. Dabei ist

  1

  Arbeitskammer,

  4

  Hochdruckgerät,

  7

  Wasserumlaufsystem,

  8

  fließendes Wasser eines Wasserversorgungssystems,

  9

  die Umkehrosmoseanlage,

  11

  Fernbedienung für das Reinigungssystem.

• 9 eine schematische Darstellung einer Vorrichtung zum Trennen von nicht vulkanisierter Gummimischung von einem Stahlcord bei Schrott / Abfall. Dabei ist

  1

  Arbeitskammer,

  2

  das automatische Tor zum Beladen von ankommenden Rohstoffen und Entladen von verarbeiteten Produkten,

  4

  Hochdruckgerät,

  5

  Reinigungssystem,

  6

  Arbeitstisch,

  7

  Wasserumlaufsystem,

  8

  fließendes Wasser eines Wasserversorgungssystems,

  12

  Wassertank.

• 10 eine schematische Darstellung einer Vorrichtung zum Trennen von nicht vulkanisiertem Gummigemischung von Stahlcord bei Schrott / Abfall, wobei:

  1

  Arbeitskammer,

  4

  Hochdruckgerät,

  5

  Reinigungssystem,

  6

  Arbeitstisch,

  7

  Wasserumlaufsystem,

  8

  Wasserversorgungssystem mit Durchflussrohr,

  9

  Umkehrosmoseanlage,

  11

  Fernbedienung für das Reinigungssystem,

  12

  Wassertank.

• 11 eine Fotografie einer Vorrichtung zum Trennen von nicht vulkanisierter Gummimischung von Stahlcord bei Schrott / Abfall, wobei:

  1

  Arbeitskammer,

  4

  Hochdruckgerät,

  5

  Reinigungssystem.

• 12 eine Fotografie einer Vorrichtung zum Trennen von nicht vulkanisierter Gummimischung von Stahlcord bei Schrott / Abfall, wobei:

  2

  automatisches Tor zum Laden von Rohstoffen und zum Entladen verarbeiteter Produkte,

  3

  Belüftungs- und elektrische Beleuchtungsanlage,

  6

  Arbeitstisch.

• 13 eine Fotografie einer Vorrichtung zum Trennen einer nicht vulkanisierten Gummimischung von Stahlcord bei Schrott / Abfall, wobei:

  7

  ein Wasserumlaufsystem ist,

  8

  ein Wasserversorgungssystem,

  9

  eine Umkehrosmoseanlage und

  10

  ein Wasserfeinfiltersystem ist.

• 14 eine Fotografie einer Vorrichtung zum Trennen von nicht vulkanisierter Gummimischung von Stahlcord bei Schrott / Abfall, wobei:

  11

  Fernbedienung der Reinigungsanlage.

• 15 eine Fotografie einer Betriebsvorrichtung zum Trennen von Gummischung von Stahlcord.
• 16 eine Tabelle, die physikalisch-mechanischen und physikalisch-chemischen Werte von nicht vulkanisierten Gummimischungen zeigt, die als Ergebnis der Verwendung erhalten wurden.

Show it:

• 1 a general view of scrap rubberized steel cord (unvulcanized rubber compound).
• 2 the extracted rubber fragments from unvulcanized rubber compound.
• 3 the extracted metal reinforcements (threads) of the steel cord.
• 4 the division of the incoming material into metal reinforcing elements and rubber fragments.
• 5 the rubber compound after processing.
• 6 a schematic representation of a device for separating an unvulcanized rubber mixture from steel cord in scrap / waste. there is

  1

  working chamber,

  2

  automatic gates for loading raw materials and unloading processed products,

  5

  cleaning system,

  6

  work table,

  8th

  running water of a water supply system with a water reverse osmosis system,

  11

  remote control for the cleaning system,

  12

  water tank.

• 7 a schematic representation of a device for separating an unvulcanized rubber mixture from steel cord in the scrap/waste. there is

  1

  working chamber,

  4

  high-pressure device,

  7

  water circulation system,

  8th

  running water of a water supply system,

  11

  remote control for the cleaning system,

  12

  water tank.

• 8th a schematic representation of a device for separating an unvulcanized rubber mixture from steel cord in scrap / waste. there is

  1

  working chamber,

  4

  high-pressure device,

  7

  water circulation system,

  8th

  running water of a water supply system,

  9

  the reverse osmosis system,

  11

  Remote control for the cleaning system.

• 9 a schematic representation of a device for separating unvulcanized rubber mixture from a steel cord in scrap / waste. there is

  1

  working chamber,

  2

  the automatic gate for loading incoming raw materials and unloading processed products,

  4

  high-pressure device,

  5

  cleaning system,

  6

  work table,

  7

  water circulation system,

  8th

  running water of a water supply system,

  12

  water tank.

• 10 a schematic representation of a device for separating unvulcanized rubber mixture from steel cord in scrap / waste, wherein:

  1

  working chamber,

  4

  high-pressure device,

  5

  cleaning system,

  6

  work table,

  7

  water circulation system,

  8th

  water supply system with flow tube,

  9

  reverse osmosis system,

  11

  remote control for the cleaning system,

  12

  water tank.

• 11 a photograph of a device for separating unvulcanized rubber compound from steel cord in scrap / waste, wherein:

  1

  working chamber,

  4

  high-pressure device,

  5

  cleaning system.

• 12 a photograph of a device for separating unvulcanized rubber compound from steel cord in scrap / waste, wherein:

  2

  automatic gate for loading raw materials and unloading processed products,

  3

  ventilation and electric lighting system,

  6

  work table.

• 13 a photograph of a device for separating an unvulcanized rubber compound from steel cord in scrap / waste, wherein:

  7

  is a water circulation system,

  8th

  a water supply system,

  9

  a reverse osmosis system and

  10

  is a fine water filter system.

• 14 a photograph of a device for separating unvulcanized rubber compound from steel cord in scrap / waste, wherein:

  11

  Remote control of the cleaning system.

• 15 Fig. 12 is a photograph of an operating device for separating rubber braiding from steel cord.
• 16 a table showing physico-mechanical and physico-chemical values of unvulcanized rubber compositions obtained as a result of use.

Rubberized steel cord is used in technical rubber products and is made from brass plated (brass spraying) carbon wire (metal) and raw (non-vulcanized) natural rubber based rubber compound in a 50/50 ratio ( 1 ). When processing steel cord, it is separated into raw (unvulcanized) rubber compound and metal.

When used, a jet of water is poured onto the rubberized steel cord of a technical rubber product (residue or waste), separating the metal from the unvulcanized (raw) rubber compound without the slightest change in the physico-mechanical and physico-chemical values of the raw rubber compound. The physico-mechanical and physico-chemical values remain at the level of the primary raw rubber mixture used for the production of rubberized steel cords. The result is rubber fragments - a raw rubber mixture ( 2 ) and “metal” - metallic reinforcing elements (threads) of a steel cord, consisting of brass-coated carbon wire ( 3 ).

The rubber compound used to rubberize the steel cord contains natural rubber (rubber content 52%), a modifying system for adhesion to the metal and adhesion promoters, chemical antioxidants, a vulcanizing group.

The use utilizes the action of water under high pressure, which breaks the bond between rubber and metal in rubberized steel cord and the tensioned state of the material increases cutting speed. Moderate energy consumption is spent on the manufacture and maintenance of the product in the deformed state, which ensures low energy consumption for processing the products after the proposed use, which is less than 1 kWh/kg and can be reduced to optimal values. The stresses applied to the processed product are much less than the stresses required to break the bond between rubber and metal in a rubberized steel cord.
There is no aggressive action when processing scrap/waste - no cutting, tearing or abrasion of the rubber. Thanks to this use, the waste recycling plant wears out much more slowly than conventional mechanical recycling plants. Reinforcing elements are completely separated from unvulcanized (raw) rubber without fouling/contaminating it with their fragments. This allows obtaining pure rubberized, unvulcanized (raw) shavings and rubber-free metal without complex multi-stage schemes for separating rubber from small fragments of reinforcing elements and without devices for removing metal cords and textile threads. This increases the end product output and reduces the amount of production waste.

To achieve the end goal, the rubberized steel cord waste is separated using service water up to 60°C or 45°C (depending on the pressure mode) at high pressure, using from 500 to 3000 bar with a flow rate of 15 to 250 l /min and over 250 l/min, i. H. with a flow rate of more than 15 liters of water per minute, resulting in a complete separation of the rubber, destroying the integrity of the incoming material (plate and asymmetric chips).

When using process water, it is recommended to use an industrial reverse osmosis system or a similar system (9) that increases the quality of the water supplied. This system softens process water, removes excess hardness salts and chlorine. From the reverse osmosis system (9) comes clean water that meets the production requirements and leads to complete separation. Also, process water after the use of the reverse osmosis system (9), as well as the method of filtering impurities in the method of complete separation of rubber from the reinforcing element (metal), increases the efficiency of the system and has a positive effect on the starting material. No volatile foreign substances get into the starting material, which has a positive effect on the physico-mechanical and physico-chemical values of the raw rubber mixture, as well as the reinforcing element (metal) ( 16 ).

By heating process water/process water to 150°C, not only the complete separation of rubber by violating the integrity of the incoming material is more quickly coped with, but also the surface of the scrap/waste of the rubberized steel cord is more effectively degreased and disinfected. In addition, the speed of rubber separation increases due to violation of the integrity of the incoming material. This effect leads to an increase in the value and, accordingly, an increase in the volume of the incoming material ( 19 ).

When the resulting rubber fragments are deformed in an aqueous medium, they can be crushed into required sizes (e.g. 10 - 400mm).

the 6 until 10 show the diagrams and the 11 until 14 show an apparatus for separating unvulcanized rubber compound from steel cord into scrap/waste. The device includes a working chamber (1), an automatic gate for the receipt of raw materials and unloading of processed products (2), a ventilation and electric lighting system (3), a high-pressure device (4), a cleaning system (5), a Working table (6), a water circulation system (7), a water supply system (8), a reverse osmosis system (9), a water fine filter system (10), remote control of the cleaning system (11), water tank (12).

In the working chamber (1), incoming raw materials are processed - scrap or waste rubberized steel cord. The working chamber (1) is equipped with an automatic gate (2) for loading incoming raw materials and unloading processed products, and is equipped with a ventilation system and electric lighting (3). The air temperature in the working chamber is kept at at least +5°C and regulated by the ventilation system.

• A) Eingehendes Material - Schrott oder Abfall von gummiertem Stahlcord in Form von Platten oder asymmetrischen Stücken wird auf dem Arbeitstisch (6) starr befestigt. Das Material wird auf Edelstahlroste gelegt. Die Maschenweite des Gitters hängt vom technischen Zustand des Endprodukts ab - Rohrgummimischung.
• B) Die Arbeitskammer (1) wird geschlossen.
• C) Der Betreiber des Hochdruckgeräts (4) startet die Anlage, bestimmt die erforderliche Druckleistung, die von 500 bis 3000 bar betragen kann und startet das Wasserversorgungssystem (8) nach einer Umkehrosmoseanlage oder ähnlicher Wasserreinigungsanlage (9).
• D) Der Betreiber des Reinigungssystems (5) startet das Reinigungssystem (5) und schaltet das Belüftungssystem (3) der Arbeitskammer (1) ein, wobei er das Temperaturregime in der Arbeitskammer (1) zum Zeitpunkt des Starts des Systems überprüft.
• E) Das Reinigungssystem (5), das vom Bediener/Betreiber über die Fernbedienung (11) gesteuert wird, bewegt sich im 2D/3D-Modus in einem Winkel von 0 bis 360 Grad über die gesamte Oberfläche des Arbeitstisches (6). Das eingehende Material wird dank des automatischen Modus des Reinigungssystems (5) mit einer eingestellten Durchgangsgrenze (von 1 bis 60 Minuten) gleichmäßig über die gesamte Oberfläche in zwei Fraktionen aufgeteilt: nicht vulkanisierte (Roh-) Gummimischung und Metall (4).
• F) Das fertige Produkt - nicht vulkanisierte (Roh-) Gummimischung und Metall - wird mechanisch oder automatisch von der Oberfläche des Arbeitstisches (6) entfernt (z. B. Verwendung eines mechanischen Rosts/Siebs zur Extraktion von nicht vulkanisierter Gummimischung). Das Metall wird vom Arbeitstisch (6) mit einem Magnetabscheider entfernt, der im Reinigungssystem (5) enthalten ist.
• G) Die fertige nicht vulkanisierte (Roh-) Gummimischung in Form von Spänen oder asymmetrischen Stücken wird in einen Trockenkammer oder auf Trockenregale gelegt.
• 3) Je nach Bestellung des Endverbrauchers kann nicht vulkanisierte (Roh-) Gummimischung den Prozess des Walzens, Raffinierens oder Kalandrierens sowie den Prozess vom Vermischen von Gummi in einer Gummi-Vermischungsmaschine - einem Extruder - durchlaufen (5).

The usage is carried out as follows.

• A) Incoming Material - Scrap or waste rubberized steel cord in the form of slabs or asymmetrical pieces is fixed rigidly on the work table (6). The material is placed on stainless steel grids. The mesh size of the grating depends on the technical condition of the final product - tubular rubber compound.
• B) The working chamber (1) is closed.
• C) The operator of the high-pressure device (4) starts the system, determines the required pressure capacity, which can be from 500 to 3000 bar, and starts the water supply system (8) after a reverse osmosis system or similar water purification system (9).
• D) The operator of the cleaning system (5) starts the cleaning system (5) and turns on the ventilation system (3) of the working chamber (1), checking the temperature regime in the working chamber (1) at the time of starting the system.
• E) The cleaning system (5), controlled by the operator/operator via the remote control (11), moves in 2D/3D mode at an angle from 0 to 360 degrees over the entire surface of the work table (6). The incoming material is divided evenly over the entire surface into two fractions thanks to the automatic mode of the cleaning system (5) with a set passage limit (from 1 to 60 minutes): unvulcanized (raw) rubber compound and metal ( 4 ).
• F) The finished product - unvulcanized (raw) rubber compound and metal - is mechanically or automatically removed from the surface of the worktable (6) (e.g. using a mechanical grate/sieve to extract unvulcanized rubber compound). The metal is removed from the work table (6) with a magnetic separator included in the cleaning system (5).
• G) The finished unvulcanized (raw) rubber compound in the form of chips or asymmetrical pieces is placed in a drying chamber or on drying racks.
• 3) Depending on the end user's order, unvulcanized (raw) rubber compound can go through the process of rolling, refining or calendering, as well as the process of rubber mixing in a rubber mixing machine - an extruder ( 5 ).

• A) Arbeitskammer (1):
  • - PVC-Profil,
  • - Doppelglasfenster Einkammer/Doppelkammer,
  • - Sandwichpaneele (zum Beispiel 28 mm),
  • - Trennwand (zum Beispiel 3200 x 2959 mm) - 2 Stk. (oben, unten - Sandwichplatte ab 28mm, Mitte - Einkammer/Zweikammer-Doppelglasfenster (z.B. 28 mm) (2 Gläser)),
  • - Trennwand (zum Beispiel 2500 x 2950 mm) - 1 Stk. (oben, unten - Sandwichplatte ab 28mm, Mitte - Einkammer- / Doppelkammer-Doppelglasfenster (z.B. 28 mm) (2 Gläser)),
  • - Trennwand (zum Beispiel 3200 x 2950 mm) - 2 Stk. (oben, unten, Mitte - Sandwichplatte (z.B. 28 mm)),
  • - Trennwand (zum Beispiel 2500 x 2500 x 2950 mm) - 1 Stk. (oben - Sandwichplatte (z.B. 28mm)),
  • - Decke - (z. B. 16 m2) (Rahmen - Führungen für Gipskartonplatte (z. B. 67 x 28 mm), Sandwichplatte Nachbehandlung)),
  • - Selbstklebender Streifen - (z.B. 40 lfm).
  Die Parameter der Arbeitskammer und die Materialien für ihre Herstellung können entsprechend den Anforderungen sowie dem Verarbeitungsvolumen von Schrott / Abfall zu gummiertem Stahlcord geändert werden.
• B) Die Belüftungsanlage (3):
  • nach Konstruktionsmerkmalen des Lüftungssystems von Waschstraßen werden unterteilt:
    • - ein System, das einen Luftstrom in Höhe des 8-10-fachen Luftaustauschs bietet, und
    • - Dehnung (Ausgabe nach außen) in Höhe des 10 -12 - fachen Luftaustauschs.
• C) Die Beleuchtungsanlage (3) der Arbeitskammer (1):
  • die Lichtstromleistung - von 600 bis 2000 Lumen, das Vorhandensein des „Flacker“-Effekts ist ausgeschlossen, die Gleichmäßigkeit der Lichtstreuung, für das Fehlen von „blinden Flecken“, „toten Winkeln“, schattiert oder schwach beleuchtete Bereiche, ist eine zusätzliche tragbare Beleuchtung wünschenswert, eine natürliche Lichtkalibrierung, für die spektrale Empfindlichkeit des Auges muss die Farbwiedergabe der hellen Tageslichtbeleuchtung (Sonnenlicht) entsprechen, der Farbwiedergabeindex beträgt mindestens 80, müssen die verwendeten Lampen gegen mechanische Beschädigungen, Vibrationen, extreme Temperaturen und hohe Drücke beständig sein.
• D) Umkehrosmoseanlage (9):
  • die Konstruktion basiert auf einem einfachen technologischen Schema. Das Ausgangswasser wird dem Umkehrosmoseelement (Umkehrosmosemembran) zugeführt, aufgrund der Membrankonstruktion wird das Wasser in Permeat (sauberes, gereinigtes Wasser) und Konzentrat (schmutziges Wasser, also Wasser mit hohem Gehalt an Schadstoffen) getrennt. Sauberes Wasser wird einem Hochdruckgerät zugeführt und Schmutzwasser (Konzentrat) wird in das Kläranlagensystem geleitet (19).
• E) Wasserumlaufsystem (7):
  • Komplettset: Rahmen, Filtersäule, Reinwassertank 2000 1, Druckerhöhungsmodul (Edelstahl), Tauchpumpe, Steuerplatine, Quarzsand, Tanküberlaufsensoren, Feinfilter, Dreiwegehahn, zusätzlicher Patronenfilter.
• G) Arbeitstisch (6):
  • Edelstahl AISI oder ähnliches Metall.
• H) Hochdruckgerät (4):
  • starker Stahlrahmen, Elektromotor von 20 bis 500 kW, Frequenzumrichter des Motors, Riemenantrieb der Pumpe mit Schutzhaube, Drei- oder Fünfkolbenpumpe mit eingebauter Schmier- und Kolbenkühlung, Booster-Kreiselpumpe, Vorratsbehälter 300 1 mit Grobfilter, Hochdruck-Sicherheitsventil, Hochdruckpumpe (HD) Trockenlaufschutz, Motorsteuerung über Sanftanlasser oder Frequenzumrichter, Industrie-Edelstahlfilter mit Beutel-Typ-Kartusche 5 oder 10 Mikron, Manometer in Hoch- und Niederdruckleitungen, das Hochdruckgerät mit einer Bedienungsanleitung, einem Zertifikat oder einer Deklaration, einer Garantie und Empfehlungen zur Sicherheit und zum Arbeitsschutz.
• I) Reinigungssystem (5):
  • Mechanisiertes System mit kontrollierter Bewegung zum Reinigen von flachen Oberflächen mit einem Winkel von 0 bis 360 Grad, maximaler Druck 100-5000 bar, minimaler Durchfluss 15 l/min - maximaler Durchfluss 1000 l/min, Rotation Drehzahl 10-1000 U/min, Fahrgeschwindigkeit 2-12 m/min, Fahrgeschwindigkeitsregelung, unabhängige Geschwindigkeitumdrehungs- und Fahrregler, kastenförmige Universalschienen, bewegliche Endschalter, austauschbares Zubehör, XY-Systemkonfiguration für Arbeiten in verschiedenen Ebenen, Reinigungsflächen in angegebenen Richtungen.
• J) Das Reinigungssystem verwendet Düsen. Die eingesetzten Düsen, auch rotierende, verfügen über spezielle Ansätze, durch die Hochdruckwasser auf das einströmende Material einwirkt und den nicht vulkanisierten (Roh-Gummi vom Verstärkungselement (Metall) ohne mechanisches Schneiden oder Zerquetschen trennt (15).
• K) Metalltrennsystem:
  • Zur zusätzlichen Reinigung der fertigen nicht vulkanisierten Gummimischung von den restlichen flüchtigen Stoffen (feindisperse Metallfraktionen) ist ein Vibrationsmagnetabscheider oder ein ähnliches Gerät am effektivsten. Technische Parameter: Kapazität ab 5 kg/h, Magnetbanddurchmesser (z.B. - 295 mm, Magnetbandgeschwindigkeit 35m/min, Magnetbreite 500 mm, Magnethöhe 130-160 mm, Motorleistung 0,75KW ·2, Außenmaße (L. B ·H) 330000 · 2000 · 1700 mm)).
• L) Nach der Trennung schließt das Produktionspersonal (Bedienungspersonal) mit speziellen Kettenschutzhandschuhen die resultierende Rohgummimischung zu einem fertigen/marktfähigen Aussehen (Handelsansicht) ab (17).
• M) Als nächstes tritt die Rohgummimischung in die Trockenkammer ein, wo die vollständige Verdampfung des Wasserkondensats erfolgt und die nicht vulkanisierte Gummimischung ihre ursprünglichen physikalisch-mechanischen Werte und physikalisch-chemischen Werte zurückgewinnen. Installierte elektrische Leistung von Luftbewegungssystemen - zum Beispiel nicht mehr als 5 kW (reversierende Ventilatoren, kW -0,75 mal 3 = 2,25; Abluftventilator, kW - 1,5, Antrieb - bis 1 kW). Eine Trocknung der Rohgummimischung ist auch technisch möglich: Lufttrocknung, Wärmetrocknung, Naturtrocknung der Rohgummimischung in speziellen Lagerräumen und Trocknungsplätzen (18).

The following systems/machines are used to separate the non-vulcanized rubber mixture from steel cord into scrap/waste:

• A) Working chamber (1):
  • - PVC profile,
  • - single-chamber/double-chamber double-glazed windows,
  • - sandwich panels (e.g. 28 mm),
  • - partition (e.g. 3200 x 2959 mm) - 2 pcs. (top, bottom - sandwich panel from 28mm, middle - one-chamber/two-chamber double-glazed window (e.g. 28 mm) (2 glasses)),
  • - partition (e.g. 2500 x 2950 mm) - 1 pc. (top, bottom - sandwich panel from 28mm, middle - single-chamber / double-chamber double-glazed window (e.g. 28 mm) (2 glasses)),
  • - partition wall (e.g. 3200 x 2950 mm) - 2 pcs. (top, bottom, middle - sandwich panel (e.g. 28 mm)),
  • - partition (e.g. 2500 x 2500 x 2950 mm) - 1 pc. (top - sandwich panel (e.g. 28mm)),
  • - ceiling - (e.g. 16 m2) (frame - guides for plasterboard (e.g. 67x28 mm), sandwich panel finishing)),
  • - Self-adhesive strips - (e.g. 40 linear metres).
  The parameters of the working chamber and the materials for its manufacture can be changed according to the needs, as well as the volume of processing from scrap / waste to rubberized steel cord.
• B) The ventilation system (3):
  • by design features of the ventilation system of car washes are divided:
    • - a system providing an air flow equal to 8-10 times the air exchange, and
    • - Elongation (output to the outside) at the level of 10 -12 times the air exchange.
• C) The lighting system (3) of the working chamber (1):
  • the luminous flux power - from 600 to 2000 lumens, the presence of the "flickering" effect is excluded, the uniformity of light scattering, for the absence of "blind spots", "dead spots", shaded or dimly lit areas is additional portable lighting desirable, a natural light calibration, for the spectral sensitivity of the eye, the color rendering must correspond to bright daylight illumination (sunlight), the color rendering index is at least 80, the lamps used must be resistant to mechanical damage, vibration, temperature extremes and high pressure.
• D) Reverse osmosis system (9):
  • the construction is based on a simple technological scheme. The output water is fed to the reverse osmosis element (reverse osmosis membrane), due to the membrane construction, the water is separated into permeate (clean, purified water) and concentrate (dirty water, i.e. water with a high content of harmful substances). Clean water is fed to a high-pressure device and dirty water (concentrate) is fed to the sewage treatment system ( 19 ).
• E) Water circulation system (7):
  • Complete set: frame, filter column, pure water tank 2000 1, pressure booster module (stainless steel), submersible pump, control board, quartz sand, tank overflow sensors, fine filter, three-way valve, additional cartridge filter.
• G) Working table (6):
  • AISI stainless steel or similar metal.
• H) High-pressure device (4):
  • Strong steel frame, electric motor from 20 to 500 kW, frequency converter of the motor, belt drive of the pump with protective hood, three or five piston pump with built-in lubrication and piston cooling, booster centrifugal pump, storage tank 300 1 with coarse filter, high-pressure safety valve, high-pressure pump (HP) dry running protection , motor control via soft starter or frequency converter, industrial stainless steel filter with bag-type cartridge 5 or 10 micron, pressure gauges in high and low pressure lines, the high pressure unit with an instruction manual, a certificate or declaration, a guarantee and recommendations on safety and labor protection.
• I) cleaning system (5):
  • Mechanized system with controlled movement for cleaning flat surfaces with an angle from 0 to 360 degrees, maximum pressure 100-5000 bar, minimum flow 15 l/min - maximum flow 1000 l/min, rotation speed 10-1000 rpm, driving speed 2-12 m/min, travel speed control, independent speed revolution and travel controls, box-shaped universal rails, movable limit switches, interchangeable accessories, XY system configuration for working in different planes, cleaning surfaces in specified directions.
• J) The cleaning system uses nozzles. The nozzles used, including rotating ones, have special lugs through which high-pressure water acts on the incoming material, separating the unvulcanized (raw rubber from the reinforcing element (metal) without mechanical cutting or crushing ( 15 ).
• K) Metal Separation System:
  • A vibrating magnetic separator or a similar device is most effective for additional cleaning of the finished unvulcanized rubber compound from the remaining volatile substances (finely dispersed metal fractions). Technical parameters: capacity from 5 kg/h, magnetic tape diameter (e.g. - 295 mm, magnetic tape speed 35m/min, magnet width 500 mm, magnet height 130-160 mm, motor power 0.75KW 2, external dimensions (L. W. H) 330000 2000 1700mm)).
• L) After separation, the production personnel (operators) with special chain protection gloves finish the resulting raw rubber compound to a finished/marketable appearance (commercial view) ( 17 ).
• M) Next, the raw rubber compound enters the drying chamber, where the complete evaporation of the water condensate occurs and the unvulcanized rubber compound recovers its original physico-mechanical values and physico-chemical values. Installed electrical power of air-moving systems - for example, no more than 5 kW (reversing fans, kW -0.75 times 3 = 2.25; exhaust fan, kW - 1.5, drive - up to 1 kW). Drying of the raw rubber mixture is also technically possible: air drying, heat drying, natural drying of the raw rubber mixture in special storage rooms and drying places ( 18 ).

The parameters of the equipment used for separating the unvulcanized rubber compound from the steel cord into rubberized steel cord scraps/waste can be changed according to the requirements as well as the processing amount of rubberized steel cord scraps/waste.

The table shows the physico-mechanical and physico-chemical values of the end product that have arisen through use ( 16 ). The values are guaranteed for up to three months (under normal conditions: humidity up to 75%, temperature 10°- 35°C). Transportation of the rubber compound is allowed at a temperature from -30 °C to +30 °C, subsequent warming up before use in a warm room at room temperature until condensation on the surface is eliminated. Mode of transport: rubber compound, in the form of plates with a Thickness of 5 - 10mm, placed on a wooden pallet with plastic foil.

Thus, an increase in efficiency with high quality is achieved. The economy is based on the fact that the raw rubber compound does not lose its properties (the rubber compound is separated from the steel cord in a technical rubber product and retains the physico-mechanical and physico-chemical values of the original raw rubber compound used for production). A reverse osmosis system or a similar water purification system (9) is used in particular to preserve the physico-mechanical and physico-chemical values of the primary/original rubber compound.

In addition, heating domestic water to 150 °C allows not only to quickly cope with the complete separation of rubber by violating the integrity of the incoming material, but also to degrease and disinfect the surface of scrap / waste rubberized steel cord. This also contributes to the preservation of the physico-mechanical and physico-chemical values of the original rubber compound. In addition, the speed of rubber separation increases due to violation of the integrity of the incoming material. This effect leads to an increase in volume of the incoming material and, accordingly, to an increase in volume of the end product (raw rubber compound and metal). This process increases profitability.

The resulting raw rubber mixture can be used both for technical purposes (tire industry, transport industry, mechanical engineering, oil and gas industry, etc.) and for widespread consumption. In addition, the invention provides a reduction in equipment wear, a reduction in energy consumption and an increase in environmental safety.

Reference List

1

working chamber

2

automatic gate

3

Ventilation and electric lighting system

4

high-pressure device

5

cleaning system

6

work table

7

water circulation system

8th

water supply system

9

reverse osmosis system; water purification plant

10

Fine water filter system

11

remote control

12

water tank

Claims (2)

Use of a water jet under pressure from 500 to 3000 bar with a flow rate of 15 l/min and higher with a reverse osmosis system or a similar water purification system (9) to separate an unvulcanized rubber compound from steel cord into scrap / rubberized steel cord waste while maintaining the physical- mechanical and physico-chemical properties/values of the original rubber compound, including the impact on the technical rubber product. Use of a water jet under pressure from 500 to 3000 bar with a flow rate of 15 l/min and higher with service/process water heating of up to 150°C for separating a non-vulcanized rubber mixture from steel cord into scrap / rubberized steel cord waste while maintaining the physical mechanical and physico-chemical values of the original rubber compound, including the impact on the technical rubber product.

Images